Molded and shaped thermoset abrasive discs

ABSTRACT

An abrasive disc that fits on a sander over all of the edges of the back up pad such that the disc itself does not have a sharp edge which can cause injuries or damage parts.

Abstract: An added molding and shaping process to flexible abrasivesanding discs slightly oversized compared to the backup pad. Possibleconfigurations include sizes of 2″,3″,5″,6″,8″, and 11″ outsidediameter. Possible grit configurations include

24, 36, 40, 50, 60, 80, 100, 120, 150, 180, 220, 320, 400, 600, 800,1000, 1200, 1500, 2000 and 3000.

Background: In my 25 year experience in distribution of coated abrasiveproducts, no company has come up with a safe solution for the followingproblems while either hand sanding or using pneumatic random orbitalsander for flexible disc sanding of wood, metals, composites, or othersubstrates.

Description: Taking an existing flat abrasive disc or punching discsfrom jumbo rolls and shaping it slightly so the outer diameter of theforms to the outside diameter of the backup pad with a tapered edge.This tapered edge will greatly reduce the chance of the disc cuttingbody parts or work pieces due to spreading the force of the dangeroussharp disc edge, so it sands instead of cuts.

I want to manufacture and market a safer line of abrasive sanding discs.

The problems of current discs on the market include:

1. Film backed discs being very sharp on the edges leading to injurywhile accidentally touching the discs while the pneumatic random orbitalsander spins at 12,000 rpm. This usually occurs when the sander is setdown after use and accidental contact is made while the disc is stillspinning. Safety is a major concern for all manufacturers as it shouldbe. In the last week, I have asked 6 different professional sandersabout hand injuries and 100% described horrific injuries. Some requiredstiches.

2. While sanding a variety of surfaces that have a 90 degree angle tothem, the sharp disc contacts the edge of where the parts meet andgouges the workpiece.

3. This can also occur and flat work pieces when the sander is set downat a slight angle.

4. When a back up pad (the part the disc attached to), gets worn orloaded, it can make the discs fly off at high speed. This turns theminto high speed cutting devices as they fly, very dangerous.

A new design of the shape of abrasive sanding discs that features aslightly oversized, tapered molded edge that curves up over the backingpad will solve the problems listed above. The discs will not have thesharp edges that lead to injuries and damage of parts in manufacturing.These can have a hook and loop backing or a pressure sensitive adhesivebacking. Possible backing methods include pressure sensitive adhesiveand hook and loop material.

The advantages of my design are:

Operator safetyLessening the risk of work surface damageLonger disc pad lifeLonger disc lifeMuch shorter distance of travel if they accidentally fly off

DESCRIPTION OF DRAWINGS

FIG. 1—A side view of the disc as it would sit on a flat surface

FIG. 2—A side view of the disc as it would sit on a flat surface

FIG. 3—A 3D view of the disc as it would sit flat

FIG. 4—A top view of the disc

FIG. 5—A bottom view of the disc

DETAILED DESCRIPTION OF INVENTION

By specifying new disc sizes from the abrasive manufacturer plant orlaser cutting or die stamping new, oversized discs, this gives and extraedge to work with. Example: A typical sanding disc is 5″ OD going on toa 4⅞″ OD back up pad. In that situation, I will start with a 5½″ OD discand form the edges so the edges extend over the back up pad.

I will accomplish that by starting with an oversized tube press withinternal, thin, welded pieces of metal that conform the individual discswith a pattern. As the discs move down the tubes (with consistent heatadded), the outside edges will conform and therefore make a tight sealover the intended back up pad when used.

1. A molded and shaped circular abrasive disc comprising: A formed shapethat is flat on the surface of the back up pad and extends up over partor all of the edges of the back up pad.